Epoxidized peroxides

ABSTRACT

ACYL PEROXIDES CONTAINING EPOXY GROUPS THAT ARE PROVIDED BY THE CONVERSION OF CARBON-TO-CARBON DOUBLE BONDS IN ETHYLENICALLY UNSATURATED PEROXIDE INTERMEDIATES TO THE CORRESPONDING EPOXIDIZED STRUCTURES. THE EPOXY PEROXIDES ARE USEFUL AS CATALYSTS, FOR EXAMPLE, IN THE PREPARATION OF EPOXY RESINS.

US. Cl. 260--348 26 Claims ABSTRACT OF THE DISCLOSURE Acyl peroxides containing epoxy groups that are provided by the conversion of carbon-to-carbon double bonds in ethylenically unsaturated peroxide intermediates to the corresponding epoxidized structures. The epoxy peroxides are useful as catalysts, for example, in the preparation of epoxy resins.

The present invention relates to a new class of epoxidized acyl peroxides prepared from corresponding ethylenically unsaturated acyl peroxides.

The peroxides of this invention have special utilities by reason of their unusual chemical structures. The foremost of these results from the epoxy groups. Having both peroxy and epoxy groups, these new compounds are unique in that they are capable of both catalyzing and cross-linking with, for example, epoxy resins. In other applications, the presence of epoxy groups, which may be derived by oxidizing ethylenically unsaturated peroxides as disclosed hereinafter, contributes the advantageous properties of an acid scavenger and stabilizer to the epoxidized derivatives. Heretofore, it has been necessary to introduce acid scavengers and reaction stabilizers as separate additives to neutralize the acidic environment required during polymerization, for example, of vinyls. When employing the epoxy peroxides of this invention as catalysts, it is necessary to add little or none of such compounds.

Additionally, glycol-containing peroxides are now obtainable by merely hydrolyzing the epOXy peroxides of this invention in the presence of Water and an acid. Heretofore, it has not been possible to obtain such glycols. If the hydroxy radicals are initially present in the reactants used for the preparation of the present peroxides, they will esterify or otherwise react so that the end product will not be a glycol. With the present compounds, the glycol can be formed after the compound is made and therefore is not involved in the preparative reaction of the peroxide.

Unsaturated polyfunctional peroxides, precursors for certain of the epoxy peroxides of this invention, are disclosed in co-pending US. patent application Ser. No. 531,352, filed Mar. 3, 1966 and now abandoned.

Broadly, the polyfunctional epoxy peroxides of this invention are defined by the following structural formula:

O O [Rat o t m IIJD wherein m and n are positive whole number integers from 0 to 1 with the proviso that the sum of m and n is always at least 1 and p is a positive whole number integer from 1 to 2. R is a phenyl radical or a saturated or ethylenically unsaturated organic radical having acyclic or cyclic configuration and which may or may not contain one or more epoxy groups. R is selected from a saturated organic acyclic or cyclic monovalent or bivalent radical, an unsaturated monovalent or bivalent radical having acyclic or cyclic configuration, a bivalent phenylene radical, an ethylenically unsaturated bivalent acyclic organic radical which may or may not contain one or more United States Patent 0 Patented Jan. 26, 1971 epoxy groups; and an acetylenically unsaturated acyclic bivalent radical. It is provided that either R or R will always contain at least one epoxy grouping. On the other hand, when R and R are acyclic each may contain more than one epoxy grouping.

Thus, when n is 1, m can be either 0 or 1 and the epoxy peroxides of this invention are defined by the following structural formula wherein m, p, R and R are defined supra.

When m, n and p are 1, 0 and 1, respectively, R is epoxy free, monovalent and saturated and R is a saturated epoxy-containing organic radical having acyclic or cyclic configuration. When m, n and p are 1, 0 and 2, respectively, R is bivalent and either saturated or acetylenically unsaturated, the R radical again containing the epoxy grouping.

When In is 0, R is saturated organic radical and is preferably of a tertiary configuration.

When m, n and p are 0, l and 2, respectively, R is an epoxy-containing, saturated, bivalent radical having cyclic or acyclic configuration and R is epoxy free. When In and n are both 1, irrespective of whether p is 1 or 2, it is preferred that the R(s) and R each contain an epoxy grouping.

In a further preferred aspect, R and R are limited to less than 20 carbon atoms each. Although it is desirable that both R and R be hydrocarbons prior to epoxidation, non-hydrocarbon substituents may be included, provided they produce no undesirable side effects.

The epoxidized peroxides defined by this invention, therefore, include (1) those diacyll peroxides having the following structural formula:

i i R-COOCR wherein R and R are similar or dissimilar saturated mono or poly epoxy-containing organic groups as defined supra when m, n and p are each 1; and (2) those peresters having the following structural formula:

(R-( i-OO),R' (3) wherein p and R are defined as set forth supra. When it is desirable to locate the epoxy group contained in the R radical at the up position relative to the carbonyl group, special techniques known in the art for epoxidation at such a location may be required.

With respect to Formula 3, when p is 1, R is a monovalent saturated organic radical, while when p is 2, R is either a bivalent saturated or acetylenically unsaturated organic radical.

Representative examples of epoxy peroxides within the scope of this invention include the following:

Acetyl-9,l0-epoxy stearoyl peroxide Bis (9,10-epoxy stearoyl) peroxide Benzoyl-9,l0-epoxy stearoyl peroxide t-Butyl per 2,3-epoxy n-butyrate Di-benzoyl epoxy succinoyl peroxide HgH converted to an epoxy grouping through any standard epoxidation reaction employing active oxygen agents such as peracetic acid, hydrogen peroxide/acetic acid with an acid catalyst, hydrogen peroxide/formic acid without an acid catalyst and the like.

Additionally, through careful control of the amount of active oxygen agent employed, partially epoxidized materials such as set forth supra are obtained. For example, in linoleoyl tetra hydrobenzoyl peroxide, by selective addition of the epoxidizing agent, the double bond located at the 9,10 position will be substantially completely con verted to an epoxy group while leaving unsaturation in the 12,13 position and in the cyclohexenoyl ring. Such compounds have the desirable feature of combining unsaturation for cross-linking reactions 'with unsaturated monomers and polymers, and stabilization of the finished polymer with epoxy groups.

The ethylenically unsaturated organic peroxides, precursors employed in the preparation of the epoxy peroxides of this invention may be obtained by the conventional techniques generally known to one skilled in this art.

perester (or diperester), conventional techniques include the reaction of a hydroperoxide (R'O-O-H) of the desired hydroxy (or dihydroxy) alkane or alkyne with an ethylenically unsaturated carboxylic acid (RCOOH),

wherein the organic radical (R) corresponds to the ethylenically unsaturated organic group desired in the ethylenically unsaturated perester precursor. In such reactions it is normally preferred to employ an acid halide, such as a chloride, of the corresponding unsaturated carboxylic acid in the reaction with the hydroperoxide to form the ester.

The preparation of an ethylenically unsaturated perester is illustrated by the following incomplete equation:

0 0 H H II RC-Cl+l-IOOR lROO-OR' aqueous This type of reaction is exemplified by the preparation of t-butyl per tetrahydrobenzoate:

A mixture of 250 ml. of water and 1.13 moles of 50% NaOH was cooled to 10 C. 0.50 mole of t butyl hydroperoxide was added to the stirred caustic solution. The mixture was then cooled to 0 C. and Triton X- and petroleum naphtha were added to the reactor. Thereafter, 0.75 mole of 3,4-tetrahydrobenzoyl chloride was added over 32 minutes at 0 to 25 C. The mixture was stirred for another two hours at these temperatures, and after the reaction was complete, was separated. The organic layer was Washed twice with cold, dilute KOH solution pH 11), twice with cold water, once with dilute cold H 80 solution (pH 1) and once more with cold water. The washes were all carried out at 10 to 15 C. with minutes of stirring. The product was dried with anhydrous Na SO filtered, and concentrated under vacuum. The product analysis was as follows: active oxygen-theoretical 8.07; actual7.64; purity of final product 94.7%; yield, percent of theoretical 87.6%.

In similar procedures, ethylenically unsaturated peresters such as t-butyl per oleate are prepared. Furthermore, by varying the stoichiometric quantities of the appropriate hydroperoxide and acid halide 2,5-dimethyl-2,5- dipertetrahydrobenzoate hexyne-3 and 2,5-dimethyl-2,5- diper tetrahydrobenzoate hexane are prepared.

UNSYMMETRICAL DIACYLS The preparation of unsymmetrical ethylenically unsaturated diacyl peroxides is conventionally accomplished by reacting the peracid of one of the desired constituents with an acid halide, preferably an acid chloride, of the other desired acyl constituent, as illustrated by the following incomplete equation:

This reaction is exemplified by the preparation of acetyl oleoyl peroxide:

A mixture of 1.0 mole of aqueous 32.66% peracetic acid (PAA) solution (mole ratio PAA/AA was 1.95) was cooled to 0 C. Sufficient Na CO was added to neutralize the acetic acid (AA) present. Then 0.9 mole of oleoyl chloride and 1.0 mole of 50% NaOH were added simultaneously over 24 minutes at from about 2 to 0 C. The reaction was completed and worked up. The product analysis was as follows: active oxy gentheoretical 4.70; actual4.06; purity of product-86.2%; yield, percent of theoretical-79.2

Here again, by varying the reactants and the stoichiometric quantities present, unsymmetrical ethylenically unsaturated diacyl peroxide such as decanoyl tetrahydrobenzoyl peroxide, di (tetrahydrobenzoyl) maleoyl peroxide, benzoyl oleoyl peroxide, di (tetrahydrobenzoyl) phthaloyl peroxide, di (tetrahydrobenzoyl) tetrahydro phthaloyl peroxide, oleoyl tetrahydrobenzoyl peroxide, oleoyl linoleoyl peroxide, crotonyl tetrahydrobenzoyl peroxide and tetrahydro benzoyl linoleoyl peroxide are prepared.

SYMMETRICAL DIACYL The symmetrical ethylenically unsaturated diacyl peroxides are generally prepared by reacting an acid chloride 7 with hydrogen peroxide in the presence of a base. For example, bis (tetrahydrobenzoyl) peroxide is prepared as follows:

A mixture of 0.55 mole of 50% HOOH and 200 ml. water were cooled to 2 C. 1.75 moles of 50% NaOH was added thereto over a 9 minute period. The temperature rose to 14 C. Triton X-100 was added to emulsify the mixture. The mixture of 1.0 mole of tetrahydrobenzoyl chloride and 100 m1. of petroleum naptha were added over 35 minutes at from 1 to 1 C. The reaction was stirred for an additional 2.5 hours at to 2 C. After the reaction was finished, it was phase separated. The organic layer was washed three times with dilute KOH solution (pH 11) and once more with water. The product was dried with anhydrous Na SO and filtered. The active TABLE I.-EPOXIDIZED PEROXIDES Percent Mole purity by Percent Mole ratio Reaction Reaction active PAA ratio PAA/ temp, tune, N9 Starting peroxide oxygen Peroxide made used FAA/AA peroxide C. hrs. product A etyl oleoyl 91. 0 Acetyl epoxy stearoyl.-- 24. 60 2. 58 1. 25/1 -24. 5 17% 1- 4552 Oleoyl 93. 0 Epoxy stearoyl 24. 14 2. 38 1. 2.5/l 46-52 3 1. 4620 Benzoyl oleoyl 90. 1 Benzoyl epoxy stearoyl. 23. 90 2. 29 1. 25/1 31-26 17% 1. 4892 Tetrahydro benzoyl. 1 63. 7 Big 3,4-ep1oxy tetrahydro 23. 46 2. 14 3. 00/1 ea. 7 ca. 99

enzoy Decanoyl tetrahydro benzoyl 88. 3 Deearoyv 3,4-ep1oxy tetra- 23. 46 2. 14 3. 00/1 ea. 7 ca. 101 1. 4597 hy r0 enzoy t-Butyl per tetrahydro benzoate. 94. 7 t-Butyl per 3,4-epoxy 23.23 2. 06 1. 50/1 3325 17% 1. 4648 tetrahydro benzoate. 2,5-dimethyl-2,5-dlpertetra- 90. 3 2,5-din1ethyl-2,5-diper 3,4- 24.03 2. 44 3 1. 50/1 30-25 17% 1. 4867 hydrobenzoate hexyne-3. Epoxy tetrahydro benzoate exyne-3.

Analysis of product oxirane oxygen analysis Active oxygen analysis Percent yield Percent Percent Percent Percent Percent Percent Percent based on which Peroxide made theory found purity theory found purity yield analysis Acetyl epoxy stearoyl 4. 4. 33 96. 4 4. 49 3. 99 88. 9 92. 7 Active oxygen. Epoxy stearoyl 5. 38 4. 87 90. 4 2. 60 2. 42 89. 6 84. 2 Oxirane oxygen. Benzoyl epoxy stearoyl 3. 82 3.63 05. 0 3.82 3. 58 03. 8 07. 5 Active oxygen. Bis 3,4-epoxy tetrahydro benzoyl. 11.34 5. 83 51. 4 5. 67 3. 24 57. 2 34. 7 Oxirane oxygen. Decanoyl 3,4-epoxy tetrahydro benzoyl 5.12 3. 75 73. 2 5.12 4. 02 96.1 70. 5 Oxirane oxygen. t-Butyl pet 3.4-tetrahydro benzoate 7. 47 6. 83 91. 4 7. 47 7. 23 96. 8 96. 6 Ox1rane oxygen. 2,5-dimethy1-2,5-diper (3,4-epoxy tetrahydro benzoate) 7. 57 6. 87 90.8 7. 57 6. 30 83. 2 81. 7 Oxirane oxygen.

hexyne-3.

1 In DMP. 2 Also done at 3.00/1 with about the same results as described.

oxygen analysis of the product was as follows: theoretical-6.39; actual-2.38. The purity and yield were 37.3% and 75.6%, respectively. Because this peroxide What is claimed: 1. An epoxidized peroxide consisting of carbon, hydrogen and oxygen atoms and having the formula:

was found to be heat unstable, dimethyl phthalate (DMP) O O was added and the petroleum naptha stripped off under vacuum and the product analyzed as follows: actual active oxygen4.07; purity-63.7%.

Here again, bis oleoyl peroxide is prepared in a similar wherein manner. 50 m and n are positive whole number integers of from To further illustrate the novel epoxy peroxides of this 0 to 1 with the proviso that the sum of mi and n is invention, the following examples are provided. It should always at least 1, p is a positive whole number integer be understood that the details thereof are not to be reof from 1 to 2, garded as limitations as they may be varied as will be R is an organic radical less than 20 carbon atoms understood by one skilled in this art. selected from the group consisting of a phenyl To individual reaction vessels containing peracetic radical, an ethylenically unsaturated monovalent acid in acetone were added 1.0 mole of various ethyleorganic radical having acyclic or cyclic configuration, nically unsaturated peroxides. The specific peroxides or a saturated monovalent organic radical having treated and the reaction conditions employed are shown acyclic or cyclic configuration, in Table I. The reactions were warmed to the desired 0 R is an organic radical of less than 20 carbon atoms temperature using a water bath. A condenser was used selected from the group consisting of a saturated to prevent loss of peracetic acid and acetone. monovalent acyclic, saturated bivalent acyclic, bi- After the reactions were completed, the reaction prodvalent phenylene, monovalent saturated cyclic, monoucts were diluted with water and some solvent, shaken, valent ethylenically unsaturated acyclic, monovalent and phase separated. The organic layers were washed 5 ethylenically unsaturated cyclic, bivalent ethylenically twice with 0.5% KOH in 5% Na SO solution and twice unsaturated acyclic, bivalent saturated cyclic, and with water. The products were dried with anhydrous bivalent acetylenically unsaturated acyclic With the Na SO filtered and concentrated under vacuum. proviso that each oxygen atom present in R or R Table I contains an analysis of the results, as well as is in the form of an epoxy grouping and that at least the specific reaction conditions employed for obtaining one epoxy grouping is always present in at least one the various epoxy peroxides. R or R, when R is a phenyl group m and n=1, when Other epoxidized peroxides of this invention such as m=0, R is free from epoxy groups, and when n=0, t-butyl per 9,10-epoxy stearate, 9,10-epoxy stearoyl-3,4 'R' is saturated or acetylenically unsaturated and free epoxy tetrahydrobenzoyl peroxide, 2,5-dimethyl-2,5-diper from epoxy groups and R is a saturated monova ent {3,4-epoxy tetrahydrcbcnzoate) hexane, di (3,4-epoxy radical having acyclic configuration.

2. An epoxidized acyl peroxide in accordance with claim 1 wherein p is l, m is l and n is l.

3. An epoxidized peroxide in accordance with claim 1 wherein p is 1, m is 1 and n is 0.

4. An epoxidized peroxide in accordance with claim 1 wherein p is 2, m is l and n is 0.

5. An epoxidized peroxide in accordance with claim 1 wherein p is 2, m is l and n is 1.

6. An epoxidized peroxide in accordance with claim 1 wherein p is 2, m is and n is 1.

7. An epoxidized peroxide in accordance with claim 2 wherein both R and R are 8,9-epoxy heptadecanyl radicals.

8. An epoxidized peroxide in accordance with claim 2 wherein R is an 8,9-epoxy heptadecanyl radical and R is a methyl radical.

9. An epoxidized peroxide in accordance with claim 2 wherein R is a phenyl radical and R is an 8,9-ep0xy heptadecanyl radical.

10. An epoxidized peroxide in accordance with claim 2 wherein R is a 3,4-epoxy cyclohexanyl radical and R is a nonanyl radical.

11. An epoxidized peroxide in accordance with claim 2 wherein both R and R are 3,4-epoxy tetrahydrobenzoyl radicals.

12. An epoxidized peroxide in accordance with claim 2 wherein R is a 3,4-epoxy cyclohexanyl radical and R is an 8,9-epoxy heptadecanyl radical.

13. An epoxidized peroxide in accordance with claim 2 wherein R is a 3,4-epoxy cyclohexanyl radical and R is l-propenyl radical.

14. An epoxidized peroxide in accordance with claim 3 wherein R is a 3,4-epoxy cyclohexanyl radical and R is a t-butyl radical.

15. An epoxidized peroxide in accordance with claim 3 wherein R is a 1,2-epoxy propanyl radical and R is a tbutyl radical.

16. .An epoxidized peroxide in accordance with claim 3 wherein R is an 8,9-epoxy heptadecanyl radical and R is a t-butyl radical.

17. An epoxidized peroxide in accordance with claim 4 wherein the Rs are 3,4-epoxy cyclohexanyl radicals and R is a 2,5-dimethyl hex-2,5-ylene radical.

18. An epoxidized peroxide in accordance with claim 4 wherein the Rs are 3,4-epoxy cyclohexanyl radicals and R is a 2,5-dimethyl, hex-3-yne-2,5-ylene radical.

19. An epoxidized peroxide in accordance with claim 5 wherein the Rs are 3,4-epoxy cyclohexanyl radicals and R is an epoxy ethylene radical.

20. An epoxidized peroxide in accordance with c aim 5 wherein the Rs are 3,4-epoxy cyclohexanyl radicals and R is a 1,2-benzenylene radical.

21. An epoxidized peroxide in accordance with claim 5 5 wherein the Rs are phenyl radicals and R is an epoxy ethylene radical.

22. An epoxidized peroxide in accordance with claim 5 wherein the Rs are a 3,4-ep0xy cyclohexanyl radical and R is a 4,5-epoxy cyclohexan-l,2-ylene radical.

23. An epoxidized peroxide in accordance with claim 5 wherein the Rs are 3,4-epoxy tetrahydrobenzoyl radicals and R is an ethenylene radical.

24. An epoxidized peroxide in accordance with claim 6 wherein the Rs are t-butyl radicals and R is a 4,5-epoxy cyclohexan-l,2-ylene radical.

25. An epoxidized peroxide in accordance with claim 2 wherein R is a 3,4-epoxy cyclohexanyl radical and R is a 8,9-11,l2-diepoxy heptadecanyl radical.

26. An epoxidized peroxide of the formula:

wherein m and n are positive whole number integers of from 0 to 1 with the proviso that the sum of m and n is always at least 1; is a positive whole number integer of from 1 to 2; and R and R are each organic radicals of less than carbon atoms, and being free of other than carbon, hydrogen and oxygen atoms, with the proviso that any oxygen present is in the form of an epoxy group, with the further proviso that at least one epoxy group is always present in at least one R or R; when p is 1, R is monovalent and when p is 2, R is bivalent, when m is 0, R is free from epoxy groups and when n is 0, R is free from epoxy groups.

References Cited UNITED STATES PATENTS 3/1966 Tinsley et a] 260348 3/1957 Frostick et al 260-348 NORMA S. MILESTONE, Primary Examiner 

